Glossary Lean Production Adding Value without Wastage CIP PULL KANBAN TPM JIT. Consulting

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1 Adding Value without Wastage CIP PULL JIT KANBAN TPM Consulting

2 CIP Continuous Improvement Process The principle of the continuous improvement constitutes a self-contained part of the management philosophy. The CIP workshop is used in order to constantly improve processes. Supervised by a moderator, employees of the most different departments optimize workstations, processes and procedures in a team. The aim is to secure and to enhance the standard step-by-step. Constant improvement in small steps Avoiding wastage Involvement of all employees Strengthening individual responsibility SMED workshops for set-up time reduction By using the SMED method (Single Minute Exchange of Dies set-up in the single digit minute range) it is possible to reduce the set-up time significantly. In the SMED method every particular work step is analyzed whether it is really necessary, whether it can be combined with other work steps and whether it can be simplifi ed. Furthermore it is possible to perform set-up processes externally, i.e. preparing and reworking in order to keep the stop of the machine during set-up as short as possible. Reduction of set-up times This enables smaller batch sizes and increases flexibility Enhanced productivity and output TPM effective machinery by preventive maintenance The total productive maintenance enhances the entire efficiency of the operational facilities continuously involving the active participation of employees. TPM is a standardized and supporting method for a medium to long term enhancement of machine availability and for the minimization of unscheduled downtimes during the manufacturing process. Improvement of working situations Enhancement of machine and plant availability Deviations become transparent and can be rectified

3 3S / 5S cleanliness and orderliness at the workstation Cleanliness and orderliness are basic prerequisites for efficient manufacturing. The 3S / 5S audit makes cleanliness and orderliness at the workstation measurable. Seiri sorting out all redundant objects Seiton straighten or set in order Seiso sweeping / systematic cleaning Shitsuke standardizing of work practices Seiketsu sustaining the discipline Avoidance of wastage caused by times for searching Enhancement of transparency More effi cient working Quality starts at the working environment Pull Principle The pull principle constitutes a method for production control. In this method, production processes are initiated by a downstream process, i.e. if no requirement is signaled by the downstream process (e.g. because all buffer stations are fully loaded), no production is initiated. This avoids an accumulation of orders in-between the processes which would increase the lead time. Short lead times and on-time shipment It is only produced what is really needed One piece flow According to the principle One piece flow, workpieces are immediately passed on from process step to process step without waiting times. This drastically reduces the lead time and unneeded workin-process. It is nearly impossible to implement the One piece flow in its purest form for a typical component manufacturing in the woodworking and furniture industry. But smaller batch sizes with short transfer times result also in positive effects. In assembly systems it is even possible to enhance productivity by applying the One piece flow because unnecessary intermediate steps (depositing / receiving of components, transport) are avoided. Shortest lead time Enhancement of productivity in assembly systems High degree of flexibility

4 Kanban self-steering control loops Kanban (Japanese: card, board, signal) is a method for steering production simply and according to demand. By means of a control mechanism this may be an empty space, a card, a bin or an electronic signal the demand of the internal customer is shown. This ensures that only the required quantity is produced (Pull principle). By this work-in-process is lowered and production to stock is avoided. Decrement of work-in-process It is only produced what really is needed Enhanced transparency and disburdening of the indirect departments The Supermarket / Minimarket Principle With the Supermarket Principle it is possible to provide parts or fittings efficiently for assembly. When a product has reached the minimum inventory, production is continued with a defined batch size or a purchase order is issued. In the Minimarket the standard parts are available at each workstation which avoids an additional effort in time caused by searching of parts. Reduction of times required for searching of parts Disburdening the planning / control Increased transparency Poka Yoke error prevention in the manufacturing process Poka Yoke is a principle with Japanese origin aiming to avoid unnecessary errors. By applying simple actions or tools unintentional errors in the manufacturing process are eliminated. In most cases these actions can already be taken during the design of the products or when setting up the workstation. Avoidance of errors Improving quality High process reliability

5 Value stream mapping design of lean processes With Value stream mapping the actual process of material and information flow is displayed graphically along the entire value creation chain from the supplier through to the customer. Based on this actual state the scope for improvement is shown and then concepts for increasing the value creation are developed. Increased share of value-adding Reduction of the lead time and on-time shipment Improvement of quality Consulting and Software for the international woodworking and furniture industry SCHULER Business Solutions AG Karl-Berner-Str PFALZGRAFENWEILER GERMANY Phone Fax Your contact: Andreas Schädle

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